The Manufacturing Engineer (WAAM Bias) designs, implements, and optimizes large‑scale Wire Arc Additive Manufacturing processes for aerospace components. This role focuses on the development of processes for complex, near‑net‑shape metallic structures from design to production, ensuring strict compliance with aviation quality and safety standards.
Key Responsibilities
- Establish, validate, and optimize WAAM deposition parameters (current, voltage, travel speed, shielding gas flow) for aerospace alloys like Titanium, Inconel, and Aluminium.
- Utilize specialized additive software to generate, simulate, and optimize multi‑axis robot/CNC deposition paths to prevent collisions and minimize thermal distortion.
- Design and execute thermal control strategies, including inter‑pass temperature monitoring and in‑process cooling, to manage residual stress and microstructural integrity.
- Lead New Product Introduction (NPI) by transforming aerospace CAD models into WAAM‑optimized, near‑net‑shape geometries ready for post‑process machining.
- Program, configure, and maintain integrated WAAM cells, including robotic manipulators (ABB), power sources (Fronius) and environmental enclosures.
- Ensure all manufacturing processes conform to aerospace standards such as AS9100 and emerging additive manufacturing regulations (e.g., ASTM F42, SAE AMS7039).
Key Skills & Competencies
- High proficiency in WAAM‑specific slicing and path‑generation software.
- Competence in programming multi‑axis industrial robots and integrating sensor feedback loops for real‑time process monitoring.
- Deep understanding of solidification mechanics, phase transformations, and defect generation (porosity, cracking) in wire‑fed arc deposition.
- Strong knowledge of how WAAM near‑net shapes interface with subsequent precision CNC machining operations.
- Mastery of problem‑solving frameworks (8D, FMEA, 5 Whys) to troubleshoot deposition anomalies and microstructural defects.
Required Skills, Qualifications and Experience
- Good working knowledge of CNC machining, turning and milling up to 5 axis with CAM software experience or working knowledge of WAAM/additive manufacturing.
- Knowledge of Lean manufacturing, Six Sigma and quality improvement tools.
- Experience with CAD software for generating 2D technical drawings.
- Solid understanding of MRP systems and experience managing BOMs and routings in SAP (or similar ERP systems).
- Hyper Mill CAM experience would be a advantage.
- Proven ability to drive cultural and process change, improving efficiency and quality.
- A collaborative mindset with a passion for continuous improvement.
- Degree or Master’s in Manufacturing, Materials Science, Aerospace, or Mechanical Engineering (a PhD or research focus heavily centered on WAAM/DED is highly desirable).
- Minimum 3 years of hands‑on experience in Directed Energy Deposition (DED), specifically Wire Arc Additive Manufacturing, within a high‑integrity engineering environment.
- Prior experience in aerospace, space‑launch systems, or defence manufacturing is required.
You will enjoy excellent work/life balance with a 4‑day week (Mon‑Thurs) and flexible working arrangements.
Lockheed Martin is committed to upholding principles of equal opportunity, fostering a work environment that is aligned with our core values of integrity, respect, and exceptional performance. We recognize the importance of leveraging the unique talents and experiences of all our employees to drive innovation, deliver superior solutions, and maximize value for our customers. Our focus is on identifying the most qualified candidate for each role, regardless of their background.
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